Processes to make water and oil repellent bcf yarn

ABSTRACT

Disclosed are processes for applying anti-soil compositions onto BCF yarns during cable or air twisting processes prior to weaving, knitting or tufting into finished carpet. The process foregoes the need for downstream environmentally unfavorable dyeing and low pH chemical treatment processes on the finished carpet. The anti-soil composition can be comprised of a high specific surface energy chemical or other material, for example a fluorochemical. Further, the anti-soil composition can further comprise an anti-stain component. Also disclosed are systems, BCF yarns, and carpets made from the BCF yarn treated by the disclosed process.

FIELD OF THE INVENTION

The invention relates to anti-soil application processes for bulkcontinuous filament (BCF) carpet and related textile fabrics, andspecifically, to processes for applying anti-soil compositions on BCFyarns during cable or air twisting processes prior to weaving, knittingor tufting. The process foregoes the need to treat carpets and othertextiles made from the BCF yarn, thus eliminating costly andenvironmentally unfavorable dyeing and low pH chemical treatmentprocesses. Also disclosed herein are systems used to apply the anti-soilformulations to the BCF yarn, and soil repellant yarns, and carpets withimproved anti-soil properties made from the BCF yarn of the disclosedprocess.

BACKGROUND OF THE TECHNOLOGY

Carpets and other fabrics are currently treated with topical chemistriesfor improved stain resistance and/or soil resistance. For nylon carpets,both stain blocker (e.g. acid dye blocker) and anti-soil withfluorochemicals are traditionally used. For polyester carpets, such as2GT and 3GT carpets, and polypropylene carpets, anti-soil chemistry maybe applied topically to the tufted carpet as part of the carpetfinishing process. Polyester and polypropylene carpets typically do notrequire a stain blocker treatment because of inherent stain resistanceto acid dyes and stains owing to their lack of amine end groups thatfunction as acid dye sites.

Topical application at the carpet mill can be in the form of exhaustapplication and spray application. Exhaust application (i.e. flex-nipprocess at high (300-400 wt. %) wet pick-up), is known to provide animprovement in efficacy over spray-on applications at 10-20 wt. % wetpick-up of anti-soil. Exhaust applications typically use higher amountsof water and energy to dry and cure the carpet than do sprayapplications. Spray-on fluorochemical products are designed to use lesswater and energy than exhaust applications, but they do not impartanti-soil properties that are as good as those provided by the exhaustapplications owing to limited depth of penetration into the fabric,especially deep pile fabrics and those incorporating the tightly twistedyarns that are now becoming more popular.

While various processes are in use in the carpet industry for the dyeingand finishing of carpets, some large scale and some small, most of thecarpet made today is dyed and finished on a continuous dye range. Thisis done mainly in one of two ways: In one case, a two stage process isemployed, where the carpet is steamed and dyed first, steamed, rinsed,and excess water extracted; then stain blocker (SB) is applied, thecarpet is again steamed and washed, and then anti-soil fluorochemical(FC) is applied in the form of a foam or liquid spray and the carpet isfinally dried. (See e.g. U.S. Pat. Nos. 5,853,814; 5,948,480 andWO2000/000691). In the second, somewhat improved case, called theco-application process, the carpet is also steamed and dyed first,steamed again, rinsed and extracted; and then a blend of SB and FC isapplied together at high wet pick up, after which the carpet andchemicals are exposed once again to steam to fix the treatment, followedby drying. (See e.g. U.S. Pat. Nos. 6,197,378 and 5,520,962). In bothcases, low pH solutions, excess water, and energy are required for theSB and FC to penetrate the carpet and achieve uniform coverage. In sum,the typical prior art process is as follows: BCF yarn→Twist→heatset→tufting→carpet→dye→stain block/anti-soil.

SUMMARY OF THE INVENTION

There is a desire to reduce the overall usage of topical anti-soilformulations, especially formulations that contain fluorochemicals, forenvironmental and cost reasons. Further, there is also a desire toreduce the amount of water and low pH chemicals used to apply theanti-stain and anti-soil formulations. Thus, processes for applying suchbeneficial compositions using less water, nominal pH chemicals, and lessenergy are in demand.

While the development of a process that eliminates the current carpettreatment systems for applying anti-stain and anti-soil compositions isdesirable; current processes do exist for good reasons. First, becausethe appearance of carpet has historically depended on the ability to dyewool or nylon or even polyester tufted carpets to the desired shade, itwould not be permissible to treat the carpet with compositions such asanti-stain or anti-soil chemistries beforehand that might interfere withthe process of uniform dyeing. Further, the dyeing process would tend toremove the topical treatment chemistries, rendering them ineffective.

Second, as mentioned above, treatment of yarn or fabric for stain andsoil resistance typically involves fixing with steam, and low pH mayalso be required especially for acid dyed fabrics. Therefore, it wasdeemed most practical to process carpets in the order described above,where carpet is formed, then steamed and dyed, steamed again, rinsed andextracted; and then SB and FC is applied, again involving steamingand/or rinsing in the various processes of the prior art.

Carpets have also long been constructed of dyed or pigmented yarns,which constructions are treated in numerous possible ways, including theoptions of further dyeing, and the application of stain and/or soilresistant compositions with the concomitant use of steam and rinsewater, as in the processes described above.

The invention disclosed herein provides a process to make textilefabrics, especially tufted articles, without the requirement forsubsequent stain and soil resistant chemistry application, thus avoidingthe cost and waste of steam fixing and rinsing attendant with suchlarge-scale fabric applications. As disclosed herein, the processinvolves application of topical chemistries to dyed or pigmented yarnsimmediately after twisting or cabling one or more such yarns together.The chemistries are then heat-set onto the twisted yarn under dryconditions, and the twisted yarn subsequently weaved or tufted into afinished fabric or carpet. Novel systems that enable the efficientapplication of topical chemistries to yarn subsequent to twisting andprior to winding and heat-setting are also disclosed.

Specifically, the disclosed process uses an atopical chemistrycomposition applicator positioned within a mechanical twisting processdownstream of the twisted yarn take-up reel and upstream of the yarnwinder. In sum, the disclosed process moves the backend, large scale andwasteful anti-soil application step, and if necessary, stain blockapplication step, up front during yarn twisting. Thus, the carpetmanufacturing process now becomes: BCF yarn→twist→FC (and optionalSB)→heat set (optionally dry heat set)→tufting→carpet. Surprisingly, thedisclosed process is as effective, or even more effective, thanprocesses of the prior art in terms of fabric soil resistance.

As describe above, the process of the disclosed invention is counterintuitive since treating the carpet yarn prior to heat setting andtufting is known to affect the quality of the finished carpet,particularly during dyeing. Further, the inventive process is alsocounter intuitive because soil resistant compositions tend to be verydifficult to apply uniformly to twisted yarn bundles at the usual linespeed without substantial waste. Moreover, the disclosed process iscounter intuitive because the prior art yarn twisting apparatuses havenot previously accepted topical chemistry applications to twisted yarnprior to winding. However, as shown below, Nylon carpets manufacturedwith the treated BCF yarn show superior anti-soil properties over thesame carpets without such treatment.

In one aspect, a process for treating twisted BCF yarn with an anti-soilcomposition comprising an anti-soil component is disclosed. The processcomprises: (a) providing twisted BCF yarn; (b) winding said BCF yarn ona take-up reel; and (c) contacting said BCF yarn with said anti-soilcomposition while said BCF yarn is in motion and prior to said BCF yarncontacting and winding up on said take-up reel. The anti-soilcomposition can be comprised of a high specific surface energy chemicalor other material, for example a fluorochemical that imparts highspecific surface energy properties such as high contact angles for waterand oil, or even a non-fluorochemical particulate material havingsimilar properties. The anti-soil composition can further comprise ananti-stain component.

In another aspect, an untufted, twisted BCF yarn comprising an anti-soilcomponent is disclosed, wherein said anti-soil component is present onsaid twisted BCF yarn prior to tufting the BCF yarn. The anti-soilcomponent is present at an on weight of fiber from about 100 ppm toabout 1000 ppm. The yarn can comprise polyamide fiber and/or havepolymer components selected from polyester and polypropylene. The yarncan be tufted and manufactured into carpet or fabrics.

In a further aspect, a process for manufacturing carpet is disclosedcomprising providing an untufted, twisted BCF yarn comprising ananti-soil component, tufting said BCF yarn, and weaving into saidcarpet. Because of the anti-soil component present on the BCF yarn priorto tufting and weaving, there is no need to treat the finished carpetwith an anti-soil composition.

In yet another aspect, a system for applying an anti-soil composition totwisted BCF fiber is disclosed. The system comprises: (a) a first yarntake-up device that receives at least two individual yarn members andtransmits a single yarn member; (b) an anti-soil composition applicatordisposed downstream of said yarn take-up device that applies saidanti-soil composition to said single yarn member; and (c) a second yarntake-up device that receives said single yarn member. The anti-soilcomposition can be comprised of a high specific surface energy chemicalor other material, for example a fluorochemical that imparts highspecific surface energy properties such as high contact angles for waterand oil, or even a non-fluorochemical particulate material havingsimilar properties. The anti-soil composition can further comprise ananti-stain component.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 shows the current cable twisting process.

FIG. 2 shows one aspect of the disclosed process.

DEFINITIONS

While mostly familiar to those versed in the art, the followingdefinitions are provided in the interest of clarity.

OWF (On weight of fiber): The amount of chemistry that was applied as a% of weight of fiber.

WPU (Wet pick-up): The amount of water and solvent that was applied oncarpet before drying off the carpet, expressed as a % of weight offiber.

DETAILED DESCRIPTION OF THE INVENTION

A process for treating twisted BCF yarn is disclosed comprisingcontacting the BCF yarn with an anti-soil composition while said yarn isin motion and prior to contacting and winding the yarn onto a take-upreel or winder to create a yarn package or cake. The anti-soilcomposition comprises an anti-soil component and is adapted to beapplied onto twisted BCF yarn at a wet pick-up of between about 5 wt. %and about 50 wt. %., including between about 10 wt. % and about 30 wt %,about 20 wt. % to about 30 wt. %, and about 10 wt. % to about 20 wt. %.The twisted BCF yarn can be optionally heat set after contacting theyarn with the anti-soil composition. Heat setting temperatures can rangefrom about 125° C. to about 200° C., including from about 160° C. toabout 195° C. Heat setting dwell times can range from about 0.5 to about4 minutes, including from about 0.5 to about 3 minute and from about 0.5to about 1 minute.

Anti-soil components for use in the disclosed anti-soil compositionsimpart high specific surface energy properties such as high contactangles for water and oil (e.g. water and oil “beads up” on surfacestreated by it). The anti-soil component can comprise a fluorochemicaldispersion, which dispersion may be predominantly either cationic oranionic, including those selected from the group consisting offluorochemical allophanates, fluorochemical polyacrylates,fluorochemical urethanes, fluorochemical carbodiimides, fluorochemicalquanidines, and fluorochemicals incorporating C-2 to C-8 chemistries.Alternatively, the fluorochemical can have less than or equal to eightfluorinated carbons, including less than or equal to six fluorinatedcarbons. Example fluorochemical anti-soil components include: DuPont TLF10816 and 10894; Daikin TG 2511, and DuPont Capstone RCP.Non-fluorinated anti-soil components can include: silicones,silsesquioxanes and fluorosilanated and fluoroalkylated particulates,anionic non-fluorinated surfactants and anionic hydrotropenon-fluorinated surfactants, including sulfonates, sulfates, phosphatesand carboxylates. (See U.S. Pat. No. 6,824,854, herein incorporated byreference).

The anti-soil compositions can also have an optional stain blockercomponent comprising an acidic moiety which associates with polymeramine end groups and protects them from staining by acidic dye stains.The general category of chemicals suitable to the process of the instantinvention can comprise any chemical that blocks positively charged dyesites. Stain blockers are available in various forms such as syntans,sulfonated novolacs, or sulfonated aromatic aldehyde condensationproducts (SACs), and/or reaction products of formaldehyde, phenol,polymethacrylic acid, maleic anyhydride, and sulfonic acid. They areusually made by reacting formaldehyde, phenol, polymethacrylic acid,maleic anyhydride, and sulfonic acid depending on specific chemistry.Further, the stain blocker is typically water soluble and generallypenetrates the fiber while the anti-soil, usually a fluorochemical, is anon-water soluble dispersion that coats the surface of fiber.

Examples of stain blockers include, but are not limited to: phenolformaldehyde polymers or copolymers such as CEASESTAIN and STAINAWAY(from American Emulsions Company, Inc., Dalton, Ga.), MESITOL (fromBayer Corporation, Rock Hill, N.C.), ERIONAL (from Ciba Corporation,Greensboro, N.C.), INTRATEX (from Crompton & Knowles Colors, Inc.,Charlotte, N.C.), STAINKLEER (from Dyetech, Inc., Dalton, Ga.),LANOSTAIN (from Lenmar Chemical Corporation, Dalton, Ga.), and SR-300,SR-400, and SR-500 (from E. I. du Pont de Nemours and Company,Wilmington, Del.); polymers of methacrylic acid such as the SCOTCHGARDFX series carpet protectors (from 3M Company, St. Paul Minn.);sulfonated fatty acids from Rockland React-Rite, Inc., Rockmart, Ga.);and stain resist chemistries from ArrowStar LLC, Dalton and Tri-Tex,Canada.

The anti-soil composition is adapted to contact the twisted BCF yarnwhile it is in motion and prior to contacting the take-up reel orwinder. Further, the anti-soil composition can be at a neutral pH (e.g.6 to 8) because the yarn can be optionally heat set after application ofthe composition. The process foregoes the need for harsh low pHchemicals.

Any suitable device that applies wet ingredients to a dry substrate canperform the contacting. Such devices include, but are not limited to:applicator pad, ceramic tip, ceramic ring, nip rollers, wet-wick,dip-tank, sprayer, and mister. Further, the contacting can be done byone or more devices, where each device can be the same or different. Forexample, two, three, or more application devices can be used to applythe anti-soil composition at different points in the process. Further,one or more application devices can apply an anti-soil component and oneor more separate devices an anti-stain component. Multiple applicationdevices and locations can provide better application uniformity whenusing certain BCF yarns.

The wet pick-up of anti-soil composition is between about 5 wt. % andabout 50 wt. %., including between about 10 wt. % and about 30 wt %,about 20 wt. % to about 30 wt. %, and about 10 wt. % to about 20 wt. %.The resulting twisted BCF yarn, if a fluorine based anti-soil componentis used, can have an on weight of fiber from about 100 ppm to about 1000ppm fluorine, including from about 100 to about 500 ppm fluorine, fromabout 200 to about 400 ppm, and from about 100 ppm to about 300 ppmfluorine. If the anti-soil composition further comprises a stainblocker, it is present on weight of fiber from about 500 ppm to about4%, including from about 1000 ppm to about 3%, from about 0.5% to about2%, and from about 0.5% to about 1%.

Common stain blockers use sulfonated moieties as part of the chemistry,which results in the presence of sulfur on the treated fiber. The sulfurcontent can range from about 50 ppm with 5% stain blocker to about 1 ppmwith 0.1% stain blocker on weight of fiber. Thus, based on the abovestain blocker concentrations, the sulfur content on weight of fiber willrange from about 0.5 ppm to about 40 ppm, including from about 1 ppm toabout 30 ppm, from about 5 ppm to about 20 ppm, and from about 5 ppm toabout 10 ppm. Sulfur content can be determined by x-ray diffraction orother methods.

The anti-soil composition can further comprise a component selected fromthe group consisting of: odor control agents, anti-microbial agents,anti-fungal agents, fragrance agents, bleach resist agents, softeners,and UV stabilizers.

The twisted BCF yarn can be made from polyamide fibers, such as thosemade from nylon 6,6, nylon 6, nylon 4,6, nylon 6,10, nylon 10,10, nylon12, its copolymers, and blends thereof. Further, the twisted BCF yarncan also have additional polymer components, such as polyester and/orpolyolefin components. The polyolefin component can be polypropylene.The additional polymer components can be incorporated with the polyamide(by melt-blend or co-polymerization) prior to making a polyamide fiber(e.g. a polyamide/polyester fiber), or can be stand-alone fibers thatare twisted with the polyamide fibers to make the twisted BCF yarn.

As stated above, the BCF yarn can be manufactured with olefin,polyamide, and/or polyester polymer components. An unexpected benefit ofthe disclosed process has been discovered in that, whereas a smallamount of anti-soil composition is applied compared to known exhaustprocesses, a high anti-soil component content, such as fluorine, isachieved on the surface of the yarn. Further, the anti-soil compositionapplied in the process of the disclosed invention can be eitherfluorochemical or non-fluorochemical based, or a mixture offluorochemical or fluoropolymer material with non-fluorinated soilresistant materials.

The disclosed process may be applied to yarns that do not requiresubsequent dyeing, having either a pigment or pigment included in theircomposition prior to twisting. The pigmented yarns can be made bysolution dyed as well as cationic and anionic dyed fibers. Yarnssuitable for use in the process may further comprise inherent stainresistance, whether by base composition as in the case of polypropyleneor polyester, or by the inclusion of strong acid functionality in thepolymer composition of the yarn, as in the case of nylon. Use of dyed orpigmented yarns (i.e. colored yarns) with the disclosed processeliminates the need for subsequent dyeing and enables the creation ofcolored carpets that are soil resistant, without the need for subsequentdyeing and soil resistant chemical application.

Where both inherently stain resistant and colored yarns are employed inthe disclosed process, then all of the cost of dyeing, and of SB/FCapplication to the tufted carpet are eliminated. As observed above, thisnot only reduces the cost of making carpets having superior performanceattributes, but also minimizes the environmental impact of carpetmanufacture by reducing water, steam and energy consumption.

The twisted BCF yarn made with the various aspects of the disclosedprocess, by itself or blended with non-treated fibers and yarns, can betufted and manufactured into carpets or fabrics. Carpets made with thetwisted BCF yarn exhibit an oil repellency rating of 5 or higher and awater repellency rating of 5 or higher.

Alternatively, the disclosed process can also be advantageously appliedin certain processes where a styling advantage might be derived fromdifferential dyeing and finishing after carpet formation. For example, asoil resistant or stain resistant twisted yarn of the disclosedinvention could optionally be tufted into a carpet among untreated yarnsprior to dyeing, thus creating an aesthetic alternative.

Further disclosed is a system for applying the anti-soil composition tothe twisted BCF yarn. The system includes: (a) a first yarn take-updevice that receives at least two individual yarn members and transmitsa single yarn member; (b) an anti-soil composition applicator disposeddownstream of the first yarn take-up device that applies the anti-soilcomposition to the single yarn member; and (c) a second yarn take-updevice that receives the single yarn member. The first yarn take-updevice can be a take-up roll or reel that can twist the at least twoindividual yarn members into a single yarn member. The individual yarnmembers can be single filaments or fibers, or yarns made from aplurality of filaments or fibers. The applicator can be any suitabledevice that applies wet ingredients to a dry substrate, including, butnot limited to: applicator pad, nip rollers, wet-wick, dip-tank,sprayer, and mister. The wet pick-up of composition is between about 5wt. % and about 50 wt. %., including between about 10 wt. % and about 30wt %, about 20 wt. % to about 30 wt. %, and about 10 wt. % to about 20wt. %. The resulting twisted BCF yarn, if a fluorine based anti-soilcomponent is used, can have an on weight of fiber from about 100 ppm toabout 1000 ppm fluorine, including from about 100 to about 500 ppmfluorine, from about 200 to about 400 ppm, and from about 100 ppm toabout 300 ppm fluorine. If the anti-soil composition further comprises astain blocker, it is present on weight of fiber from about 500 ppm toabout 4%, including from about 1000 ppm to about 3%, from about 0.5% toabout 2%, and from about 0.5% to about 1%. The second yarn take-updevice can be a winder.

FIG. 1 shows the current cable twisting process. Here, creel yarn 10 andbucket yarn 15, which is fed at a spindle speed of 7000 rpm, passthrough an anti-balloon device 20 and onto a take-up roll 25. From here,the twisted yarn 30 is wound up on a winder 35. FIG. 2 shows one aspectof the disclosed process. Here, creel yarn 110 and bucket yarn 115,which is fed at a spindle speed of 7000 rpm, pass through anti-balloondevice 120 and onto a take-up roll 125. An anti-soil compositionapplicator 140 is disposed downstream of take-up roll 125, which appliesan anti-soil component to the twisted yarn 130. From here, the twistedand treated yarn is wound up on a winder 135.

The disclosed process is counterintuitive and surprisingly results inyarn that contains acceptable anti-soil properties when manufacturedinto a carpet or fabric. One would expect that rearranging the processas described above would fowl up down-stream carpet manufacturingprocesses and lead to poor quality carpet. Thus, the results reportedbelow are surprising and unexpected.

EXAMPLES

The following are examples of nylon 6,6 carpets made from two 922 denierbeige color solution dyed BCF fibers that have been treated variousaspects of the process disclosed above and similar fibers with notreatment. Selection of alternative anti-soil components and stainblocker components, fibers and textiles having different surfacechemistries will necessitate minor adjustments to the variables hereindescribed.

Test Methods

Acid Dye Stain Test.

Acid dye stain resistance is evaluated using a procedure modified fromthe American Association of Textile Chemists and Colorists (AATCC)Method 175-2003, “Stain Resistance: Pile Floor Coverings.” 9 wt % ofaqueous staining solution is prepared, according to the manufacturer'sdirections, by mixing cherry-flavored KOOL-AID® powder (Kraft/GeneralFoods, White Plains, N.Y., a powdered drink mix containing, inter alia,FD&C Red No. 40). A carpet sample (4×6-inch) is placed on a flatnon-absorbent surface. A hollow plastic 2-inch (5.1 cm) diameter cup isplaced tightly over the carpet sample. Twenty ml of the KOOL-AID®staining solution is poured into the cup and the solution is allowed toabsorb completely into the carpet sample. The cup is removed and thestained carpet sample is allowed to sit undisturbed for 24 hours.Following incubation, the stained sample is rinsed thoroughly under coldtap water, excess water is removed by centrifugation, and the sample isdried in air. The carpet sample was visually inspected and rated forstaining according to the FD&C Red No. 40 Stain Scale described in AATCCMethod 175-2003. Stain resistance is measured using a 1-10 scale. Anundetectable test staining is accorded a value of 10.

Oil and Water Repellency Tests

The following liquids were used for oil repellency tests.

Rating Number Liquid Composition 1 Kaydol (Mineral Oil) 2 65%/35%Kaydol/n-Hexadecane 3 n-Hexadecane 4 n-Tetradecane 5 n-Dodecane 6n-Decane

The following liquids were used for water repellency tests

Liquid Composition Rating Number % Isopropanol % Water 1 2 98 2 5 95 310 90 4 20 80 5 30 70 6 40 60

Repellency Test Procedure

Five drops of rating number 1 liquid are placed from a height of 3 mmonto the carpet surface. If after 10 seconds, four out of the five dropswere still visible as spherical to hemispherical, the carpet is given apassing rating. Repeat the test with a higher rating number liquid. Therepellency rating of the sample is the highest rating number liquid usedto pass the repellency test. Carpets with a rating of 4 or higher havegood anti-soiling properties. Without anti-soil treatment, most nyloncarpets have a rating of 1 for both oil and water repellency.

Example 1 Comparative

Two 922 denier beige color solution dyed Nylon 66 BCF made from cationicdyeable polymer were cable twisted on a Volkman at 7000 rpm to form a6.0 tpi two ply yarn using the process described in FIG. 1. The windingspeed was about 50 ypm. The cable twisted yarn was subsequently heat-seton a Suessen with 200° C. dry air. The holdup time in the channel wasabout 60 seconds. The heat treated yarn was converted into a 35 oz persquare yard, 1/12 gauge, ⅜″ pile height cut pile carpet.

Example 2 Inventive

Two 922 denier beige color solution dyed Nylon 66 BCF made from cationicdyeable polymer were cable twisted on a Volkman at 7000 rpm to form a6.0 tpi two ply yarn using the process described in FIG. 2. The windingspeed was about 50 ypm. A chemical applicator was inserted between thetake up roll and winder as described in FIG. 3 option A. A ½ inch widecotton wick (Wet Wick by Perperell MA) was used to apply 50% A-201anti-soil chemical onto the cable twisted yarn at a wet-pickup of about20 wt %. The cable twisted yarn went through the wet wick at about 50ypm. The cable twisted yarn was subsequently heat-set on a Suessen with200° C. dry air. The holdup time in the channel was about 60 seconds.The heatset yarn was analyzed to have 925 ppm Fluorine. The heat treatedyarn was converted into a 35 oz per square yard, 1/12 gauge, ⅜″ pileheight cut pile carpet.

Example 3 Inventive

Two 922 denier beige color solution dyed Nylon 66 BCF made from cationicdyeable polymer were cable twisted on a Volkman at 7000 rpm to form a6.0 tpi two ply yarn using the process described in FIG. 2. The windingspeed was about 50 ypm. A chemical applicator was inserted between thetake up roll and winder as described in FIG. 2. A ½ inch wide cottonwick (Wet Wick by Perperell MA) was used to apply 25% A-201 anti-soilchemical onto the cable twisted yarn. The cable twisted yarn wentthrough the wet wick at about 50 ypm. The cable twisted yarn wassubsequently heat-set on a Suessen with 200° C. dry air. The holdup timein the channel was about 60 seconds. The heatset yarn was analyzed tohave 445 ppm Fluorine. The heat treated yarn was converted into a 35 ozper square yard, 1/12 gauge, ⅜″ pile height cut pile carpet.

Example 4 Inventive

Two 922 denier beige color solution dyed Nylon 66 BCF made from cationicdyeable polymer were cable twisted on a Volkman at 7000 rpm to form a6.0 tpi two ply yarn using the process described in FIG. 2. The windingspeed was about 50 ypm. A chemical applicator was inserted between thetake up roll and winder as described in FIG. 2. A ½ inch wide cottonwick (Wet Wick by Perperell MA) was used to apply 12.5% A-201 anti-soilchemical onto the cable twisted yarn. The cable twisted yarn wentthrough the wet wick at about 50 ypm. The cable twisted yarn wassubsequently heat-set on a Suessen with 200° C. dry air. The holdup timein the channel was about 60 seconds. The heatset yarn was analyzed tohave 270 ppm Fluorine. The heat treated yarn was converted into a 35 ozper square yard, 1/12 gauge, ⅜″ pile height cut pile carpet.

Table 1 below reports the repellency and stain tests of the fourexamples. Here, carpets made from the treated BCF yarn show excellentand good oil and water repellency ratings. This indicates that thedisclosed inventive process is an acceptable replacement to existingexhaust type applications for applying anti-soil compositions to carpetsand fabrics.

TABLE 1 Example Oil Rating Water Rating Stain Rating Remarks 1 1 1 10 norepellency 2 6 6 10 excellent repellency 3 6 6 10 excellent repellency 45 5 10 good repellency

The invention has been described above with reference to the variousaspects of the disclosed treatment process, treated fibers, carpets,fabrics, and systems used to apply anti-soil compositions to BCF yarn.Obvious modifications and alterations will occur to others upon readingand understanding the proceeding detailed description. It is intendedthat the invention be construed as including all such modifications andalterations insofar as they come within the scope of the claims.

1. A process for treating twisted BCF yarn with an anti-soil compositioncomprising an anti-soil component comprising: a. providing twisted BCFyarn; b. winding said BCF yarn on a take-up reel; and c. contacting saidBCF yarn with said anti-soil composition while said BCF yarn is inmotion and prior to said BCF yarn contacting and winding up on saidtake-up reel.
 2. The process of claim 1, further comprising dry heatsetting said BCF yarn after contacting said BCF yarn with said anti-soilcomposition.
 3. The process of claim 1, wherein said anti-soil componentcomprises a fluorochemical.
 4. The process of claim 1, wherein theanti-soil composition has a pH from about 3 to about
 8. 5. The processof claim 3, wherein said fluorochemical is selected from the groupconsisting of: fluorochemical allophanates, fluorochemicalpolyacrylates, fluorochemical urethanes, fluorochemical carbodiimides,fluorochemical quanidines, and fluorochemicals incorporating C-2 to C-8chemistries.
 6. The process of claim 3, wherein said fluorochemical hasless than or equal to six fluorinated carbons.
 7. The process of claim3, wherein said fluorochemical is a fluorochemical urethane.
 8. Theprocess of claim 1, wherein said anti-soil composition further comprisesa component selected from the group consisting of: odor control agents,anti-microbial agents, anti-fungal agents, fragrance agents, bleachresist agents, softeners, and UV stabilizers.
 9. The process of claim 1,wherein said anti-soil composition further comprises an anti-staincomponent.
 10. The process of claim 9, wherein said anti-stain componentis selected from the group consisting of: syntans, sulfonated novolacs,sulfonated aromatic aldehyde condensation products (SACs) and/orreaction products of formaldehyde, phenol, polymethacrylic acid, maleicanyhydride, and sulfonic acid.
 11. The process of claim 9, wherein saidanti-stain component is present at an on weight of fiber from about 500ppm to about 4%.
 12. The process of claim 9, wherein said anti-soilcomposition further comprises a component selected from the groupconsisting of: dye auxiliaries, sequestrants, pH control agents, andsurfactants.
 13. The process of claim 2, wherein said heat setting isperformed at a temperature from about 125° C. to about 200° C.
 14. Theprocess of claim 1, wherein said BCF yarn comprises polyamide fiber. 15.The process of claim 14, wherein said polyamide fiber is selected fromthe group consisting of: nylon 6,6, nylon 6, nylon 4,6, nylon 6,10,nylon 10,10, nylon 12, its copolymers, and blends thereof.
 16. Theprocess of claim 1, wherein said BCF yarn comprises a polymer componentselected from the group consisting of polyester and polyolefin.
 17. Theprocess of claim 1, wherein said anti-soil component is present at an onweight of fiber from about 100 ppm to about 1000 ppm.
 18. The process ofclaim 1, wherein said contacting is performed by a device selected fromthe group consisting of: applicator pad, ceramic tip, ceramic ring,wet-wick, dip-tank, sprayer, and mister.
 19. The process of claim 1,wherein said BCF yarn is dyed or pigmented prior to contacting with saidanti-soil composition.
 20. The process of claim 18 wherein a pluralityof devices are used to perform said contacting.
 21. The process of claim20, wherein said plurality of devices are different.
 22. An untufted,twisted BCF yarn comprising an anti-soil component present on a surfaceof said untufted, twisted BCF yarn.
 23. The untufted, twisted BCF yarnof claim 22, wherein said anti-soil component comprises afluorochemical.
 24. The untufted, twisted BCF yarn of claim 23, whereinsaid fluorochemical is selected from the group consisting of:fluorochemical allophanates, fluorochemical polyacrylates,fluorochemical urethanes, fluorochemical carbodiimides, fluorochemicalquanidines, and fluorochemicals incorporating C-2 to C-8 chemistries.25. The untufted, twisted BCF yarn of claim 22, further comprising ananti-stain component, wherein said anti-stain component is present onsaid twisted BCF yarn prior to tufted said BCF yarn.
 26. The untufted,twisted BCF yarn of claim 22, wherein said anti-soil component ispresent at an on weight of fiber from about 100 ppm to about 1000 ppm.27. The untufted, twisted BCF yarn of claim 22, wherein said BCF yarncomprises polyamide fiber.
 28. The untufted, twisted BCF yarn of claim27, wherein said polyamide fiber is selected from the group consistingof: nylon 6,6, nylon 6, nylon 4,6, nylon 6,10, nylon 10,10, nylon 12,its copolymers, and blends thereof.
 29. The untufted, twisted BCF yarnof claim 22, wherein said BCF yarn comprises a polymer componentselected from the group consisting of polyester and polyolefin.
 30. Theuntufted, twisted BCF yarn of claim 22, wherein said BCF yarn ispigmented or dyed.
 31. A carpet comprising twisted BCF yarn, whereinsaid twisted BCF yarn comprises the twisted BCF yarn from claim 22 thathas been tufted.
 32. The carpet of claim 31 having an oil repellencyrating of at least
 5. 33. A process for manufacturing carpet comprising:a. providing an untufted, twisted BCF yarn comprising an anti-soilcomponent present on a surface of said untufted, twisted BCF yarn; b.tufting said BCF yarn; and c. weaving said tufted BCF yarn into saidcarpet, wherein said process foregoes the need to further treat saidcarpet with an anti-soil composition.
 34. The process of claim 33,wherein said untufted, twisted BCF yarn comprises polyamide fiber. 35.The process of claim 34, wherein said polyamide fiber is selected fromthe group consisting of: nylon 6,6, nylon 6, nylon 4,6, nylon 6,10,nylon 10,10, nylon 12, its copolymers, and blends thereof.
 36. A systemfor applying an anti-soil composition to twisted BCF fiber comprising:a. a first yarn take-up device that receives at least two individualyarn members and transmits a single yarn member; b. an anti-soilcomposition applicator disposed downstream of said yarn take-up devicethat applies said anti-soil composition to said single yarn member; andc. a second yarn take-up device that receives said single yarn member.37. The system of claim 36, wherein said applicator is selected from thegroup consisting of: applicator pad, ceramic tip, ceramic ring,wet-wick, dip-tank, sprayer, and mister.
 38. The system of claim 36,wherein a plurality of applicators is used to apply said anti-soilcomposition.
 39. The system of claim 38, wherein said plurality ofapplicators are different.